Storage and retrieval system transport vehicle

ABSTRACT

An autonomous transport vehicle includes a frame forming a payload section configured to hold one or more pickfaces, a transfer arm movably mounted to the frame, a drive section connected to the frame, and a controller connected to the drive section, the controller being configured to effect an on-the-fly sortation of pickfaces carried by the autonomous transport vehicle according to a predetermined case out order sequence where the controller commands the drive section so that two or more pickfaces are picked from one or more first case unit holding locations and placed at one or more different second case unit holding locations according to the predetermined case out order sequence.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Non-Provisional patentapplication Ser. No. 15/003,983, filed on Jan. 22, 2016 (now U.S. Pat.No. 9,850,079, issued Dec. 26, 2017), which claims priority from and thebenefit of U.S. Provisional Patent Application No. 62/107,135 filed onJan. 23, 2015, the disclosures of which are incorporated by referenceherein their entireties.

This application is also related to U.S. patent application Ser. No.14/966,978 filed on Dec. 11, 2015; U.S. patent application Ser. No.14/997,902 filed on Jan. 18, 2016; U.S. patent application Ser. No.14/997,925 filed on Jan. 18, 2016; U.S. patent application Ser. No.14/997,920 filed on Jan. 18, 2016 (now U.S. Pat. No. 9,856,083, issuedJan. 2, 2018); and U.S. patent application Ser. No. 14/997,892 filed onJan. 18, 2016, the disclosures of which are incorporated hereinreference in their entireties.

BACKGROUND 1. Field

The exemplary embodiments generally relate to material handling systemsand, more particularly, to transport and sorting of items within thematerial handling system.

2. Brief Description of Related Developments

Multilevel storage and retrieval systems may e used in warehouses forthe storage and retrieval of goods. Generally the transportation ofgoods into and out of the storage structure is done with lifts fortransfer to a vehicle on a storage level, vehicles travelling up rampsto a predetermined storage level, or with vehicles that include liftstraveling along guide ways. Throughput of these storage and retrievalsystems may be limited by one or more of the retrieval of the goods at astorage level and the transfer of goods between storage levels.

It would advantageous to increase vehicle payload handling throughput bycombining movement of payload handling manipulation axes of a transportvehicle and sorting of payloads on the transport vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the disclosed embodiment areexplained in the following description, taken in connection with theaccompanying drawings, wherein:

FIG. 1 is a schematic illustration of an automated storage and retrievalsystem accordance with aspects of the disclosed embodiment;

FIGS. 1A and 1B are schematic illustrations of portions of the automatedstorage and retrieval system in accordance with aspects of the disclosedembodiment;

FIG. 2 is a schematic illustration of a transport vehicle in accordancewith aspects of the disclosed embodiment;

FIGS. 2A-2F are schematic illustrations of portions of the transportvehicle in accordance with aspects of the disclosed embodiment;

FIG. 3 is a schematic illustration of a portion of the transport vehicleof FIG. 2 in accordance with aspects of the disclosed embodiment;

FIGS. 4-9 are schematic illustrations of exemplary payload manipulationswith the transport vehicle of FIG. 2 in accordance with aspects of thedisclosed embodiment;

FIGS. 10, 11 and 12 are exemplary flow diagrams in accordance withaspects of the disclosed embodiment;

FIG. 13 is a schematic illustration of a portion of the storage andretrieval system of FIG. 1;

FIG. 14 is an exemplary flow diagram in accordance with aspect of thedisclosed embodiment;

FIG. 15 is a schematic illustration of an operator station of thestorage and retrieval system in accordance with aspects of the disclosedembodiment; and

FIG. 16 is an exemplary flow diagram in accordance with aspects of thedisclosed embodiment.

DETAILED DESCRIPTION

FIG. 1 is a schematic illustration of an automated storage and retrievalsystem 100 in accordance with aspects of the disclosed embodiment.Although the aspects of the disclosed embodiment will be described withreference to the drawings, it should be understood that the aspects ofthe disclosed embodiment can be embodied many forms. In addition, anysuitable size, shape or type of elements or materials could be used.

In accordance with aspects of the disclosed embodiment the automatedstorage and retrieval system 100 may operate in a retail distributioncenter or warehouse to, for example, fulfill orders received from retailstores for case units such as those described in U.S. patent applicationSer. No. 13/326,674 filed on Dec. 15, 2011, the disclosure of which isincorporated by reference herein in its entirety. For example, the caseunits are cases or units of goods not stored in trays, on totes or onpallets (e.g. uncontained). In other examples, the case units are casesor units of goods that are contained in any suitable manner such as intrays, on totes or on pallets. In still other examples, the case unitsare a combination of uncontained and contained items. It noted that thecase units, for example, include cased units of goods (e.g. case of soupcans, boxes of cereal, etc.) or individual goods that are adapted to betaken off of or placed on a pallet. In accordance with the aspects ofthe disclosed embodiment, shipping cases for case units (e.g. cartons,barrels, boxes, crates, lugs, or any other suitable device for holdingcase units) may have variable sizes and may be used to hold case unitsin hipping and may be configures so they are capable of being palletizedfor shipping. It is noted that when, for example, bundles or pallets ofcase units arrive at the storage and retrieval system the content ofeach pallet may be uniform (e.g. each pallet holds a predeterminednumber of the same item—one pallet holds soup and another pallet holdscereal) and as pallets leave the storage and retrieval system thepallets may contain any suitable number and combination of differentcase units (e.g. a mixed pallet where each mixed pallet holds differenttypes of case units—a pallet holds a combination of soup and cereal)that are provided to, for example the palletizer in a sorted arrangementfor forming the mixed pallet. In the embodiments the storage andretrieval system described herein may be applied to any environment inwhich case units are stored and retrieved. As may also be realized, asillustrated in FIG. 15, in one aspect of the disclosed embodiment thesystem 100 operating for example as a retail distribution center mayserver to receive uniform pallet loads of cases, breakdown the palletgoods or disassociate the cases from the uniform pallet loads intoindependent case its handled individually by the system, retrieve andsort the different cases sought by each order into corresponding groups,and transport and sequence the corresponding groups of cases (in themanner described herein) at an operator station 160EP where items arepicked from the different case units CU, and/or the different case unitsCU themselves, are placed in one or more bag(s), tote(s) or othersuitable container(s) TOT by an operator 1500, or any suitableautomation, in a predetermined order sequence of picked items accordingto, for example, an order, fulfilling one or more customer orders, inwhich the case units CU are sequenced at the operator station 160EP,noting that the sequencing of the case units CU as described hereineffects the sequencing of the case units at the operator station 160EP.

The automated storage and retrieval system 100 may include inputstations 160IN (which include depalletizers 160PA and/or conveyors 160CAfor transporting items to lift modules for entry into storage) andoutput stations 160UT (which include palletizers 160PB, operatorstations 160EP and/or conveyors 160CB for transporting case units fromlift modules for removal from storage), input and output vertical liftmodules 150A, 150B (generally referred to as lift modules 150—it isnoted that while input and output lift modules are shown, a single liftmodule may be used to both input and remove case units from the storagestructure), a storage structure 130, and a number of autonomous roversor transport vehicles 110 (referred to herein as “bots”). It is notedthat the depalletizers 160PA may be configured to remove case units frompallets so that the input station 160IN can transport the items to thelift modules 150 for input into the storage structure 130. Thepalletizers 160PB may be configured to place items removed from thestorage structure 130 on pallets for shipping.

The storage structure 130 may include multiple storage rack modulesconfigured in a three dimensional array RMA that are accessible bystorage or deck levels 130L. Each storage level 130L includes storagespaces 130S formed by the rack modules where the rack modules includeshelves that are disposed along storage or picking aisles 130A which,e.g., extend linearly through the rack module array and provide accessto the storage spaces 130S and transfer decks 130B over which the bots110 travel on a respective storage level 130L for transferring caseunits between any of the storage spaces 130S of the storage structure130 (e.g. on the level which the bot 110 is located) and any of the liftmodules 150 (e.g. each of the bots 110 has access to each storage space130S on a respective level and each lift module 150 on a respectivestorage level 130L). The transfer decks 130B are arranged at differentlevels (corresponding to each level 130L of the storage and retrievalsystem) that may be stacked one over the other or horizontally offset,such as having one transfer deck 130B at one end or side of the storagerack array or at several ends or sides of the storage rack array asdescribed in, for example, U.S. patent application Ser. No. 13/326,674filed on Dec. 15, 2011 the disclosure of which is incorporated herein byreference in its entirety. The transfer decks 130B are substantiallyopen and configured for the undeterministic traversal of bots 110 acrossand along the transfer decks 130B. As may be realized, the transferdeck(s) 130B at each storage level 130L communicate with each of thepicking aisles 130A on the respective storage level 130L, and bots 110bi-directionally traverse between the transfer deck(s) 130B and pickingaisles 130A on each storage level 130L to access the storage spaces 130Sdisposed in the rack shelves alongside each of the picking aisles 130A(e.g. bots 110 may access storage spaces 130S distributed on both sidesof each aisle such that the bot 110 may have a different facing, as willbe described in greater detail below, when traversing each picking aisle130A). As noted above, the transfer deck(s) 130B also provide bot 110access to each of the lifts 150 on the respective storage level 130Lwhere the lifts 150 feed and remove case units to and/or from eachstorage level 130L where the bots 110 effect case unit transfer betweenthe lifts 150 and the storage spaces 130S. Each storage level 130L mayalso include charging stations 130C for charging an on-board powersupply of the hots 110 on that storage level 130L such as described in,for example, U.S. patent application Ser. No. 14/209,086 filed on Mar.13, 2014 and Ser. No. 13/325,823 filed on Dec. 15, 2011 the disclosuresof which are incorporated herein by reference in their entireties.

The bots 110 may be any suitable independently operable autonomoustransport vehicles that carry and transfer case units throughout thestorage and retrieval system 100. In one aspect the bots 110 areautomated, independent (e.g. free riding) autonomous transport vehicles.Suitable examples of bots can be found in, for exemplary purposes only,U.S. patent application Ser. No. 13/326,674 filed on Dec. 15, 2011; U.S.patent application Ser. No. 12/757,312 filed on Apr. 9, 2010 (now U.S.Pat. No. 8,425,173); U.S. patent application Ser. No. 13/326,423 filedon Dec. 15, 2011; U.S. patent application Ser. No. 13/326,447 filed onDec. 15, 2011 (now U.S. Pat. No. 8,965,619); U.S. patent applicationSer. No. 13/326,505 Dec. 15, 2011 (now U.S. Pat. No. 8,696,010); U.S.patent application Ser. No. 13/327,040 filed on Dec. 15, 2011 (now U.S.Pat. No. 9,187,244); U.S. patent application Ser. No. 13/326,952 filedDec. 15, 2011; U.S. patent application Ser. No. 13/326,993 filed on Dec.15, 2011; and U.S. patent application Ser. No. 14/486,008 filed on Sep.15, 2014, the disclosures of which are incorporated by reference hereinin their entireties. The bots 110 may be configures to place case units,such as the above described retail merchandise, into picking stock inthe one or more levels of the storage structure 130 and then selectivelyretrieve ordered case units, e.g. according to a predetermined order outsequence, for shipping the ordered case units to, for example, a storeor other suitable location. The order out sequence, in one aspect,corresponds to an order in which the case units (or pickfaces as will bedescribed below) are needed for placement on an outbound pallet or inany other suitable transport device such as one or more bag(s), tote(s),shopping carriage(s), truck(s) or other suitable container fill withoutpalletization. In other aspects the order out sequence may be anysuitable predetermined sequence in which the case units or pickfaces areto be delivered to the output station by the bots 110.

The bots 110, lift modules 150 and other suitable features of thestorage and retrieval system 100 are controlled by, for example, one ormore central system control computers (e.g. control server) 120 through,for example, any suitable network 180. In one aspect the network 180 isa wired network, a wireless network or a combination of wireless andwired networks using any suitable type and/or number of communicationprotocols. In one aspect, the control server 120 includes a collectionof substantially concurrently running programs (e.g. system managementsoftware) for substantially automatic control of the automated storageand retrieval system 100. The collection of substantially concurrentlyrunning programs, for example, being configured to manage the storageand retrieval system 100 including, for exemplary purposes only,controlling, scheduling, and monitoring the activities of all activesystem components, managing inventory (e.g. which case units are inputand removed, the order in which the cases are removed and where the caseunits are stored) and pickfaces (e.g. one or more case units that aremovable as a unit and handled as a unit by components of the storage andretrieval system), and interfacing with a warehouse management system2500. The control server 120 may, in one aspect, be configured tocontrol the features of the storage and retrieval system in the mannerdescribed herein. For simplicity and ease of explanation the term “caseunit(s)” is generally used herein for referring to both individual caseunits and pickfaces.

Referring now to FIG. 2, the bots 110, as noted above, transport caseunits between each lift module 150 and each storage space 130S on arespective storage level 130L. The bots 110 include a frame 110F havinga drive section 110DR and a payload section 110PL. The drive section110DR includes one or more drive wheel motors each connected to arespective drive wheel(s) 202. In this aspect the bot 110 includes twodrive wheels 202 located on opposite sides of the bot 110 at end 110E1(e.g. first longitudinal end) of the bot 110 for supporting the bot 110on a suitable drive surface however, in other aspects any suitablenumber of drive wheels are provided on the bot 110. In one aspect eachdrive wheel 202 is independently controlled so that the bot 110 may besteered through a differential rotation of the drive wheels 202 while inother aspects the rotation of the drive wheels 202 may be coupled so asto rotate at substantially the same speed. Any suitable wheels 201 aremounted to the frame on opposite sides of the bot 110 at end 110E2 (e.g.second longitudinal end) of the bot 110 for supporting the bot 110 onthe drive surface. In one aspect the wheels 201 are caster wheels thatfreely rotate allowing the bot 110 to pivot through differentialrotation of the drive wheels 202 for changing a travel direction of thebot 110. In other aspects the wheels 201 are steerable wheels that turnunder control of, for example, a bot controller 1100 (which isconfigured to effect control of the bot 110 as described herein) forchanging a travel direction of the bot 110. In one aspect the bot 110includes one or more guide wheels 110GW located at, for example, one ormore corners of the frame 110F. The guide wheels 110GW may interfacewith the storage structure 130, such as guide rails (not shown) withinthe picking aisles 130A, on the transfer deck 130B and/or at transferstations for interfacing with the lift modules 150 for guiding the bot110 and/or positioning the bot 110 a predetermined distance from alocation to/from which one or more case units are placed and/or pickedup as described in, for example, U.S. patent application Ser. No.13/326,423 filed on Dec. 15, 2011 the disclosure of which isincorporated herein by reference in its entirety. As noted above, thebots 110 may enter the picking aisles 130A having different facingdirections for accessing storage spaces 130S located on both sides ofthe picking aisles 130A. For example, the bot 110 may enter a pickingaisle 130A with end 110E2 leading the direction of travel or the bot mayenter the picking aisle 130A with end 110E1 leading the direction oftravel.

The payload section 110PL of the bot 110 includes a payload bed 110PB, afence or datum member 110PF, a transfer arm 110PA and a pusher bar ormember 110PR. In one aspect the payload bed 110PB includes one or morerollers 110RL that are transversely mounted (e.g. relative to alongitudinal axis LX or X direction of the bot 110) to the frame 110F sothat one or more case units carried within the payload section 110PL canbe longitudinally moved (e.g. justified with respect to a predeterminedlocation of the frame/payload section and/or a datum reference of one ormore case units) along the longitudinal axis of the bot, e.g., toposition the case unit at a predetermined position within the payloadsection 110PL and/or relative to other case units within the payloadsection 110PL (e.g. longitudinal forward/aft justification of caseunits). In one aspect the rollers 110RL may be driven (e.g. rotatedabout their respective axes) by any suitable motor for moving the caseunits within the payload section 110PL. In other aspects the bot 110includes one or more longitudinally movable pusher bar (not shown) forpushing the case units over the rollers 110RL for moving the caseunit(s) to the predetermined position within the payload section 110PL.The longitudinally movable pusher bar may be substantially similar tothat described in, for example, U.S. patent application Ser. No.13/326,952 filed on Dec. 15, 2011, the disclosure of which waspreviously incorporated by reference herein in its entirety.

Referring also to FIGS. 2A and 2B and 3, the case units are placed onthe payload bed 110PB and removed from the payload bed 110PB with thetransfer arm 110PA. The transfer arm 110PA includes a lift mechanism orunit 200 located substantially within the payload section 110PL. Thelift mechanism 200 provides both gross and fine positioning of pickfacescarried by the bot 110 which are to be lifted vertically into positionin the storage structure 130 for picking and/or placing the pickfacesand/or individual case units to the storage spaces 130S (e.g. on arespective storage level 130L on which the bot 110 is located).Referring also to FIG. 1A the rack module array RMA of the storagestructure 130 includes vertical support members 1212 and horizontalsupport members 1200. Rails 1200S may be mounted to one or more of thevertical and horizontal support members 1212, 1200 in, for example,picking aisles 130A and be configured so that the bots 110 ride alongthe rails 1200S through the picking aisles 130A. The picking aisles 130Aof each storage level 130L may have one or more storage shelf levelsaccessible by the bot from the rails 1200S (e.g. from a common pickingaisle deck). As can be seen in FIGS. 1A and 1B there are one or moreshelf rails 1210 vertically spaced (e.g. in the Z direction) from oneanother to form multiple stacked storage spaces 130S each beingaccessible by the bot 110 from the common rails 1200S. As may berealized, the horizontal support members 1200 also form shelf rails (inaddition to shelf rails 1210) on which case units are placed.

The lift mechanism 200 is configured so that combined robot axis movesare performed (e.g. combined substantially simultaneous movement of thepusher bar 110PR, lift mechanism 200, pick head extension and fore/aftjustification mechanism(s) such as, e.g., the longitudinally movablepusher bar described above), so that different/multi-sku payload arehandled by the bot, and/or so that a single drive effects both a lifting(e.g. vertical movement) and an extension (e.g. lateral movement) of thearm 110PA. FIGS. 2A and 2B are schematic illustrations of the liftingmechanism 200 removed from the frame 110F. The actuation of the liftingmechanism 200 is independent of actuation of the pushes bar 110PR aswill be described below. The decoupling of the lift mechanism 200 andpusher bar 110PR axes provides for combined pick/place sequenceseffecting a decreased pick/place cycle time, increased storage andretrieval system throughput and/or increased storage density of thestorage and retrieval system. For example, the lift mechanism 200provides for picking and placing case units at multiple elevated storageshelf levels accessible from a common picking aisle deck (see FIG. 1Aand as described in, for example, U.S. patent application Ser. No.14/966,978 filed on Dec. 11, 2015 and U.S. Provisional PatentApplication No. 62/091,162 filed on Dec. 12, 2014, the disclosures ofwhich are incorporated by reference herein in their entireties). Thelift mechanism 200 also provides for the simplification and reduction ofmechanical components (e.g., motors for driving the lift and extensionaxes of the transfer arm are located off of the pick head 270) whichyields gains in reducing weight of the bot 110 and increasing themechanical stroke of the transfer arm 110PA in the z and/or y (e.g.lateral) directions.

The lifting mechanism may be configured in any suitable manner so that apick head 270 of the bot 110 bi-directionally moves along the Z axis(e.g. reciprocates in the Z direction—see FIG. 2). In one aspect, thelifting mechanism includes a mast 200M and the pick head 270 is movablymounted to the mast 200M in any suitable manner. The mast is movablymounted to the frame in any suitable manner so as to be movable alongthe lateral axis LT (e.g. the Y direction) of the bot 110. In one aspectthe frame includes guide rails 210A, 210B to which the mast 200 isslidably mounted. A transfer arm drive 250A (see FIGS. 2A and 3), 250Bmay be mounted to the frame for effecting at least movement of thetransfer arm 110PA along the lateral axis LT (e.g. Y axis) and the Zaxis. Referring to FIGS. 2, 2A and 3, in one aspect the transfer armdrive 250A, 250B includes an extension motor 301 and a lift motor 302.The extension motor 301 may be mounted to the frame 110F and coupled tothe mast 200M in any suitable manner such as by a belt and pulleytransmission 260A (similar to belt and pulley transmission 260Bdescribed below), a screw drive transmission (not shown) and/or a geardrive transmission (not shown). The lift motor 302 may be mounted to themast 200M and coupled to pick head 270 by any suitable transmission,such as by a belt and pulley transmission 271, a screw drivetransmission (not shown) and/or a gear drive transmission (not shown).As an example, the mast 200M includes guides, such as guide rails 280A,280B, along which slide members 281A, 281B ride. The pick head 270 ismounted to the slides 281A, 281B for guided movement in the Z directionalong the guide rails 280A, 280B. In other aspects the pick head ismounted to the mast in any suitable manner for guided movement in the Zdirection. The belt 271B of the belt and pulley transmission 271 isfixedly coupled to the pick head 270 so that as the belt 271 moves (e.g.is driven by the motor 302) the pick head 270 moves with the belt 271and is bi-directionally driven along the guide rails 280A, 280B in the Zdirection. As may be realized, where a screw drive is employed to drivethe pick head 270 in the Z direction, a nut may be mounted to the pickhead 270 so that as a screw is turned by the motor 302 engagementbetween the nut and screw causes movement of the pick head 270.Similarly, where a gear drive transmission is employed a rack and pinionor any other suitable gear drive may drive the pick head 270 in the Zdirection. In other aspects any suitable linear actuators are used tomove the pick head in the Z direction.

Referring again to FIGS. 2, 2A, 2B and 3, as described above, thelifting of the pick head 270 and lateral extension of the transfer arm110PA is provided by lift motor 302 and extension motor 301. In otheraspects the lifting of the pick head 270 and lateral extension of thetransfer arm 110PA may be provided by a remotely actuated brakemechanism 298 such that a single motor 301A moves the pick head 270 inthe Z direction and laterally extends the transfer arm 110PA (e.g. bylaterally moving the mast 200M). For example, the remotely actuatedbrake mechanism 298 is configured to selectively switch (e.g. under thecontrol of the bot controller 110C) between drive belts 260, 271B forselectively lifting/lowering the pick head 270 and laterally extendingthe transfer arm 110PA. As may be realized, a single motor effectingboth lifting/lowering and extension of the transfer arm 110PA reduces anumber of mechanical components and electrical interfaces of the bot 110as well as reduces the weight of the bot 110. With the remotely actuatedbrake mechanism 298 the lateral extension of the transfer arm 110PA maybe substantially similar to that described above with motor 301, e.g.,where the motor 301A drives a belt and pulley transmission 260A. Themast 200M may be fixedly coupled to the belt 260 so that as the belt isdriven by the motor 301A the mast 200M moves with the belt 260. A brakemechanism 266 may be connected to the controller 110C and be configuredto effect selective disengagement of the mast 200M from the belt 260 andlaterally fix the mast 200M at a predetermined lateral position. As maybe realized, any suitable sensors and/or encoders may be provided andconnected to the controller 110C to sense or otherwise detect a lateralposition of the mast 200M (and hence the pick head 270) relative to theframe 110F and/or a case unit pick/place location. The brake mechanism266 also includes a transmission that selectively couples (e.g. whenbelt 260 is decoupled from the mast 200M) the belt 260 to belt 260A.Belt 260A is coupled, via the brake mechanism 266, to and drives a lifttransmission 267 mounted to the mast 200M. The lift transmission 267 iscoupled to the belt 271B such as through pulleys for lifting loweringthe pick head 270 in the Z direction.

Referring now to FIGS. 2C-2F the pick head 270 of the bot 110 transferscase units between the bot 110 and a case unit pick/place location suchas, for example, the storage spaces 130S and/or interfaces between thebot 110 and a lift module 150 (such as the interfaces described in, forexample, U.S. Provisional Patent Application No. 62/104,520 filed onJan. 16, 2015, the disclosure of which is incorporated by referenceherein in its entirety). In one aspect, the pick head 270 includes abase member 272, one or more tines or fingers 273A-273E and one or moreactuators 274A, 274B. The base member 272 is mounted to the mast 200M,as described above, so as to ride along the guide rails 280A, 280B. Theone or more tines 273A-273E are mounted to the base member 272 at aproximate end of the tines 273A-273E so that a distal end of the tines273A-273E (e.g. a free end) is cantilevered from the base member 272.Referring again to FIG. 1B, the tines 273A-273E are configured forinsertion between slats 1210S that form a case unit support plane CUSPof the storage shelves.

One or more of the tines 273A-273E is movably mounted to the base member272 (such as on a slide/guide rail similar to that described above) soas to be movable in the Z direction. In one aspect any number of tinesare mounted to the base member 272 while in the aspect illustrated inthe figures there are, for example, five tines 273A-273E mounted to thebase member 272. Any number of the tines 273A-273E are movably mountedto the base member 272 while in the aspect illustrated in the figures,for example, the outermost (with respect to a centerline CL of the pickhead 270) tines 273A, 273E are movably mounted to the base member 272while the remaining tines 273B-273D are immovable relative to the basemember 272.

In this aspect the pick head 270 employs as few as three tines 273B-273Dto transfer smaller sized case units (and/or groups of case units) toand from the bot 110 and as many as five tines 273A-273E to transferlarger sized case units (and/or groups of case units) to and from thebot 110. In other aspects, less than three tines are employed (e.g. suchas where more than two tines are movably mounted to the base member 272)to transfer smaller sized case units. For example, in one aspect all butone tine 273A-273E is movably mounted to the base member so that thesmallest case unit being transferred to and from the bot 110 withoutdisturbing other case units on, for example, the storage shelves has awidth of about the distance X1 between slats 1210S (see FIG. 1B).

The immovable tines 373B-373D are used when transferring all sizes ofcase units (and/or pickfaces) while the movable tines 373A, 373E areselectively raised and lowered (e.g. in the Z direction) relative to theimmovable tines 373B-373D to transfer larger case units (and/orpickfaces). Referring to FIGS. 2C and 2D an example is shown where allof the tines 273A-273E are positioned so that a case unit supportsurface SF of each tine 273A-273E is coincident with a picking plane SPof the pick head 270. FIGS. 2E and 2F illustrate an example were the twoend tines 273A, 273E are positioned lower (e.g. in the Z direction)relative to the other tines 273B-273D so that the case unit supportsurface SF of tines 273A, 273E is offset from (e.g. below) the pickingplane SP so that the tines 273A, 273E do not contact the one or morecase units carried by the pick head 270 and do not interfere with anyunpicked case units positioned in storage spaces 130S on the storageshelves or any other suitable case unit holding location.

The movement of the tines 273A-273E in the Z direction is effected bythe one or more actuators 274A, 274B mounted at any suitable location ofthe transfer arm 110PA. In one aspect, the one or more actuators 274A,274B are mounted to the base member 272 of the pick head 270. The one ormore actuators are any suitable actuators, such as linear actuators,capable of moving one or more tines 273A-273E in the Z direction. In theaspect illustrated in, for example, FIGS. 2B-2F there is one actuator274A, 274B for each of the movable tines 273A, 273E so that eachmoveable tine is independently movable in the Z direction. In otheraspects one actuator may be coupled to more than one movable tine sothat the more than one movable tines move as a unit in the Z direction.

As may be realized, movably mounting one or more tines 273A-273E on thebase member 272 of the pick head 270 provides for full support of largecase units and/or pickfaces on the pick head 270 while also providingthe ability to pick and place small case units without interfering withother case units positioned on, for example, the storage shelves. Theability to pick and place variably sized case units without interferingwith other case units on the storage shelves reduces a size of a gap GP(see FIG. 1A) between case units on the storage shelves. In this aspect,having three fixed, e.g. relative to the base member 272, tines273B-273D and two movable, e.g. relative to the base member 272, tines273A, 273E provides for fewer moving tines which means fewer drivemotors, fewer guides, fewer sensors, less complexity, less botmanufacturing costs and less weight disposed on the mast 200M (whichassists in sizing the lift motor 301, 301A an other structuralcomponents of the mast 200M). In addition, as may be realized, becausethe tines 273B-273D are fixed to the base member 272 there is noduplicative motion when picking/placing case units as the lifting andlowering of case units and/or pickfaces to and from the case unitholding location is effected solely by the lift motor 301, 301A. Smalleractuators 274A, 274B may also be utilized to selectively lift and lowerthe tines as the actuators are lifting only the respective tines (e.g.without a case unit supported thereon) such that once the tines arealigned with the picking plane SP the tines are locked in place and donot move.

Referring again to FIGS. 2 an 3, it is again noted that the pusher bar110PR is movable independent of the transfer arm 110PA. The pusher bar110PR is movably mounted to the frame in any suitable manner such as by,for example, a guide rod and slide arrangement and is actuated along theY direction (e.g. in a direction substantially parallel to theextension/retraction direction of the transfer arm 110PA). In one aspectat least one guide rod 360 is mounted within the payload section 110PLso as to extend transversely relative to the longitudinal axis LX of theframe 110F. The pusher bar 110PR may include at least one slide member360S configured to engage and slide along a respective guide rod 360. Inone aspect, at least the guide rod/slide arrangement holds the pusherbar 110PR captive within the payload section 110PL. The pusher bar 110PRis actuated by any suitable motor and transmission, such as by motor 303and transmission 303T. In one aspect the motor 303 is a rotary motorsubstantially similar to motor 301, 301A, 302 and the transmission 303Tis substantially similar to the belt and pulley transmissions describedabove. In other aspects the pusher bar 110PR may be actuated by a linearactuator having substantially no rotary components.

The pusher bar 110PR is arranged within the payload section 110PL so asto be substantially perpendicular to the rollers 110RL and so that thepusher bar 110PR does not interfere with the pick head 270. As can beseen in FIG. 3, the bot 110 is in a transport configuration where atleast one case unit would be supported on the rollers 110RL (e.g. therollers collectively form the payload bed). In the transportconfiguration the tines 273A-273E of the pick head 270 areinterdigitated with the rollers 110RL and are located below (along the Zdirection) a case unit support plane RSP (see FIG. 4) of the rollers110RL. The pusher bar 110PR is configured with slots 351 into which thetines 273A-273E pass where sufficient clearance is provided within theslots 351 to allow the tines to move below the case unit support planeRSP and to allow free movement of the pusher bar 110PR withoutinterference from the tines 273A-273E. The pusher bar 110PR alsoincludes one or more apertures through which the rollers 110RL passwhere the apertures are sized to allow free rotation of the rollersabout their respective axes. As may be realized, the independentlyoperable pusher bar 110PR does not interfere with the rollers 110PR,extension of the transfer arm 110PA in the transverse direction (e.g. Ydirection) and the lifting/lowering of the pick head 270.

As noted above, because the pusher bar 110PR is a separate, standaloneaxis of the bot 110 that operates free of interference from the pickhead 270 extension and lift axes, the pusher bar 110PR can be operatedsubstantially simultaneously with the lifting and/or extension of thetransfer arm 110PA. The combined axis moves (e.g. the simultaneousmovement of the pusher bar 110PR with the transfer arm 110PA extensionand/or lift axes) provides for increased payload handling throughput.For example, referring to FIGS. 4-5, during a transfer arm 110PApick/place sequence the pusher bar 110PR is repositioned (as the caseunit(s) and/or pickface are being picked and transferred into thepayload section 110PL) to a location that is a predetermined distance X2away from the contact depth X3 (e.g. the depth of the tines occupied bythe case unit(s) and/or pickface CU when being picked/placed from astorage space or other case unit holding location) (FIG. 10, Block1000). The distance X2 is a minimized distance that only allowssufficient clearance between pusher bar 110PR and the case unit(s) toallow the case unit(s) to be seated on the rollers 110RL. As the caseunit(s) CU are lowered onto the rollers 110RL (FIG. 10, Block 1010) thedistance travelled by the pusher bar 110PR to contact the case unit(s)CU is a shorter distance X2 when compared to moving from a back side 402(relative to the lateral direction and an access side 401 of the payloadsection 110PL) of the payload section 110PL a distance X4 as withconventional transport vehicles. When the case unit(s) CU are lowered bythe transfer arm 110PA and transferred to the rollers 110RL so as to besolely supported by the rollers 110RL, the pusher bar 110PR is actuatedto forward (relative to the lateral direction and an access side 401 ofthe payload section 110PL) justify the case unit(s) CU (FIG. 10, Block1020). For example, the pusher bar 110PB may push the case unit(s) CUlaterally the Y direction so that the case unit(s) contact the fence110PF (which is located at the access side 401 of the payload section110PL so that a case unit reference datum may be formed through contactbetween the case unit(s) CU and the fence 110PF. In one aspect thepusher bar 110PR may engage or otherwise grip the case unit(s) CU duringtransport of the case units (e.g. so as to hold the case unit(s) againstthe fence 110PF) for maintaining the case unit(s) CU in a predeterminedspatial relationship with each other and a reference frame REF (FIG. 2)of the bot 110 (FIG. 10, Block 1030). When placing the case unit(s) thepusher bar 110PR, after justifying the case unit(s) CU against the fence110PF, is withdrawn (e.g. in the Y direction) from contact with the caseunit(s) CU (FIG. 10, Block 1040). Substantially immediately after thepusher bar 110PR disengages the case unit(s) CU one or more of the liftaxis (e.g. in the Z direction) and extension axis (e.g. in the Ydirection) of the transfer arm 110PA are actuated substantiallysimultaneously with the withdrawing movement of the pusher bar 110PR(FIG. 10, Block 1050). In one aspect both the lift and extension axesare actuated when the pusher bar is withdrawn from contact with the caseunit(s) CU while in other aspect one of the lift and extension axes isactuated. As may realized, the simultaneous movement of the transfer arm110PA lift axis and/or extension axis with the withdrawal of the pusherbar 110PR as well as the decreased distance the pusher moves to justifythe case unit(s) CU decreases the time needed to transfer case unit(s)CU to and from the bot 110 and increases throughput of the storage andretrieval system 100.

In another aspect of the disclosed embodiment, multiple case units canbe substantially simultaneously carried and manipulated within thepayload section 110PL to further increase throughput of the storage andretrieval system 100. In one aspect the manipulation of the case unitsCU is a sorting of the case units where the cases are positioned on thetransfer arm 110PA for picking/placement of the case units and/orpositioned so that the case units are not transferred and remain on thetransfer arm 110PA while other case units are transferred to and fromthe transfer arm 110PA. Here, the bot 110 picks one or more case unitsfrom storage with a common transfer arm where placement of the caseunits on the common transfer arm corresponds to a predetermined orderout sequence as will be described in greater detail below (e.g. the caseunits are sorted on-the-fly (e.g. during transport with the bot 110 orotherwise while being held in a payload section of or by the bot 110while the bot is travelling along a surface or is stationary)). As anexample of case manipulation on the bot 110, referring to FIGS. 6-9,case unit(s) CUA may be picked from a case unit holding location (e.g.such as storage spaces 130S, a lift transfer station and/or a bufferstation) and transferred into the payload section 110PL (FIG. 11, Block1100). As the case unit(s) CUA is being transferred into the payloadsection 110PL the pusher bar 110PR may be pre-positioned (FIG. 11, Block1104) adjacent the fence 110PF so that the pusher bar 110PR ispositioned between the case unit(s) CUA and the fence 110PF when thecase unit(s) CUA is lowered for transfer to the rollers 110RL (FIG. 11,Block 1105). The pusher bar 110PR is actuated to push the case unit(s)CUA (resting on the rollers 110RL) in the Y direction towards the back(e.g. rear) 402 of the payload section 110PL so that the case unit(s)CUA contacts a justification surface 273JS (FIG. 2E) of the tines273A-273E and is justified to the back 402 of the payload section 110PL(FIG. 11, Block 1110).

In one aspect, where the bot 110 traverses the picking aisle 130A and/ortransfer deck 130B prior to picking subsequent case units, the pusherbar 110PR remains in contact with (e.g. grips) the case unit(s) CUAduring transport of the case unit(s) between case unit holding locationsso that the case unit(s) CUA remain in a predetermined location at theback 402 of the payload section 110PL (and/or at a predeterminedlocation longitudinally) relative to the reference frame REF of the bot110 (FIG. 11, Block 1115). To pick subsequent case units the pusher bar110PR is moved in the Y direction to disengage the case unit(s) CUA andthe lift and extension axes of the transfer arm 110PA are actuated toretrieve another case unit(s) CUB from a case unit holding location(e.g. such as storage spaces 130S, a lift transfer station and/or abuffer station) (FIG. 11, Block 1120). While the case unit(s) CUB arebeing picked the pusher bar 110PR is positioned in the Y directionadjacent the back 402 of the payload section 110PL so as to be locatedbetween the case units CUA and the justification surface 273JS of thetines 273A-273E (FIG. 11, Block 1125). The case unit(s) CUB aretransferred into the payload section and lowered/placed on the rollers110RL (FIG. 11, Block 1130) so that the case units CUA, CUB are arrangedrelative to each other along the Y axis. The pusher bar 110PR isactuated in the Y direction to push the case units CUA, CUB towards thefence 110PF to forward justify the case units CUA, CUB (FIG. 11, Block1134) and grip/hold the case units CUA, CUB for transport (FIG. 11,Block 1135). As may be realized, in one aspect the case units CUA, CUBmay be placed at a case unit holding location together (FIG. 11, Block1140) while in other aspects the case units CUA, CUB may be transportedto and placed at separate case unit holding locations.

Where the case units CUA, CUB are sorted (FIG. 11, Block 1150) forplacement at separate locations, the case units CUA, CUB are separatedfrom each other in the payload section 110PL. For example, the pick head270 of the transfer arm 110PA may be moved in the Z direction to liftthe case units CUA, CUB from the rollers 110RL by an amount sufficientto allow the pusher bar 110PR to pass beneath the case unit(s) (FIG. 12,Block 1150A). As the case units CUA, CUB are lifted the pusher bar 110PRis positioned along the Y direction so as to be located between the caseunits CUA, CUB (see FIG. 9) (FIG. 12, Block 1150B). The pick head 270 islowered so that the case units CUA, CUB are transferred to the rollers110RL and so that the pusher bar is inserted between the case units CUA,CUB (FIG. 12, Block 1150C). The pusher bar 110PR is moved in the Ydirection (e.g. to separate the case unit(s)) to move case unit(s) CUAtowards the back 402 of the payload section 110PL (e.g. against thejustification surface 273JS of the tines 273A-273E or any other suitableposition) while the case unit(s) CUB remain at the front of the payloadsection 110PL adjacent the fence 110PF (e.g. as shown in FIG. 7) (FIG.12, Block 1150D). As may be realized, where the case units are heldagainst the justification surface 273JS of the tines during transport,the pusher bar is moved in the Y direction (e.g. to separate the caseunit(s)) to move case unit(s) CUB towards the front 401 of the payloadsection 110PL (e.g. against the fence 110PF or any other suitableposition) while the case unit(s) CUA remain at the back of the paysection 110PL adjacent the justification surface 273JS. The pusher bar110PR may also be moved in the Y direction to re-justify the caseunit(s) CUB against the fence 110PF to position the case unit(s) on thetines 273A-273E for placement at a case unit holding location (FIG. 12,Block 1150E). As may be realized, with the case unit(s) CUA beingpositioned substantially against the justification surface 273JS of thetines 273A-273E (e.g. of the pick head 270) the case unit(s) CUB can beplaced at a case unit holding location substantially withoutinterference from the case unit(s) CUA (FIG. 12, Block 1150F), e.g. thecase unit CUA is free from contacting case units disposed at the caseunit holding location. The case unit(s) CUA is lowered/transferred backinto the payload section 110PL (e.g. by retracting and lowering thetransfer arm 110PA) (FIG. 12, Block 1150G). The pusher bar 110PR, whichis pre-positioned between the justification surface 273JS and the caseunit(s) CUA, pushes the case unit(s) CUA, which is disposed on therollers 110RL, against the fence 110PF to forward justify the caseunit(s) CUA for placement at another case unit holding location (e.g.different than the holding location that case unit(s) CUB were placed)(FIG. 12, Block 1150H). The pusher bar 110PR remains against the caseunit(s) CUA for gripping (e.g. with the fence) the case unit(s) duringtransport to the other case unit holding location (FIG. 12, Block1150I). The pusher bar 110PR moves away from the case unit(s) CUA andthe transfer arm is actuated to lift and extend the pick head 270 forplacing the case unit(s) CUA at the other case unit holding location(FIG. 12, Block 1150J).

An example of a case unit(s) pick and place operation with on-the-flysortation of the case units will be described with respect to FIG. 13for creating a mix pallet load according to a predetermined order outsequence in and/or in the predetermined order sequence (e.g. an orderout sequence) of picked items according to, for example, an order,fulfilling one or more customer orders, in which case units CU aresequenced for placement in one or more bag(s), tote(s) or othercontainer(s) TOT at an operator station 160EP (as shown in FIG. 15). Thebot 110 picks one or more case unit(s), CUA, CUB (see FIG. 7) from oneor more case unit holding location(s). As noted above, the case unitholding location(s) include input lift modules 150A1, 150A2, outboundlift modules 150B1, 150B2, transfer or buffer stations LTS forinterfacing with the lift modules 150A1, 150A2, 150B1, 150B2 and storagespaces 130S1-130S4. In one aspect, the case units CUA, CUB are pickedfrom the same location (e.g. such as lift module 150A1 or 150A2). Inanother aspect the case units CUA, CUB are picked from two different(e.g. a first and a second) locations (e.g. such as lift modules 150A1and 150A2) where the pusher member 110PR justifies one or more of thecase units CUA, CUB picked from the first location so that the otherone(s) of the case units CUA, CUB can be picked from the second locationin a manner substantially similar to that described above.

In one aspect input lift modules 150A1, 150A1 may receive dissimilartypes (or in other aspects the same type) of case units from theirrespective pallets where the case units are to be stored in the same (ordifferent) picking aisles. Rather than have two separate bots 110 pickthe case units from each of input lift modules 150A1, 105A2 a single bot110 picks up both case units CUA, CUB from the input lift modules 150A1,150A2 with a common transfer arm 110PA and transfers the case units CUA,CUB to their respective predetermined storage spaces 130S1-130S4. Thebot 110 traverses the transfer deck 130B and enters a predeterminedpicking aisle 130A1, 103A2 to which the one or more of the case units isto be placed. As an example, the bot 110 enters picking aisle 130A1 andplaces case unit(s) CUB at storage space 130S3 in a manner substantiallysimilar to that described above where the case units CUA, CUB areseparated from one another on the pick head 270 by pusher bar 110PR sothat case unit(s) CUB is transferred to storage space 130S3 free frominterference from case unit(s) CUA. In one aspect the bot 110 continuesto traverse picking aisle 130A1 to storage spaces 130S4 where caseunit(s) CUA are placed by the bot 110. In other aspects the case unit(s)CUA, CUB are placed in any suitable picking aisle and case unit holdinglocation, such as in different picking aisles, in different storagespaces, in the same picking aisle and/or in the same storage space.

As may be realized, and as noted above, case units are output from thestorage and retrieval system in a predetermined sequence to fulfillcustomer orders and build mixed shipping pallets. Here, the case unitsCUA, CUB are sorted by the bot into one or more predetermined case unitholding locations according to the predetermined case unit outputsequence as the case units are output from the storage and retrievalsystem. For example, assuming customer orders require case unit(s) CUCto be delivered to output lift 150B1 and case unit(s) CUD to bedelivered to output lift 150B2, the bot 110 enters picking aisle 130A1and picks case unit CUC from storage space 130S1 (FIG. 14, Block 1400).The case unit(s) CUC may be justified on the bot 110 towards the rear ofthe payload section 110PL as described above (FIG. 14, Block 1405). Thebot travels through the picking aisle 130A2 and picks case unit(s) CUDfrom a different storage space 130S2 with the common transfer arm 110PAso that both case unit(s) CUC, CUD are located adjacent one another onthe common transfer arm 110PA (FIG. 14, Block 1410). In other aspectsboth case units CUC, CUD are picked by the common transfer arm 110PAfrom a common storage space 130S (FIG. 14, Block 1415). As may berealized, in one aspect, the controller 110C is configured to effectpicking of the case unit(s) in an order that is opposite an order inwhich the case unit(s) are placed. The bot 110 grips both case unitsCUC, CUD within the payload section 110PL and exits the picking aisle130A2 (FIG. 14, Block 1420). The bot travels along the transfer deck andinterfaces with output lift 150B2 (FIG. 14, Block 1421). The botseparates the case units CUC, CUD within the payload section 110PL, asdescribed above, so that case unit(s) CUD is justified towards the frontof the payload section 110PL and case unit(s) CUC is justified towardsthe back of the payload section 110PL (FIG. 14, Block 1425). The caseunit CUD is transferred to the output lift 150B2 directly by the bot 110(e.g. the pick head 270 of the bot interfaces directly with a shelf ofthe lift) or indirectly such as through the transfer/buffer station LTS(the case unit is transferred to the station LTS and the stationinterfaces with the shelf of the lift) (FIG. 14, Block 1430). The botretracts the transfer arm 110PA to return the case unit(s) CUC to thepayload section 110PL (FIG. 14, Block 1435) and grips the case unit CUC(FIG. 14, Block 1420). The case unit(s) CUC is transported to outputlift 150B1 (FIG. 14, Block 1421), justified toward the front of thepayload section 110PL (FIG. 14, Block 1425), as described above, andtransferred to output lift 150B1 either directly or indirectly, asdescribed above (FIG. 14, Block 1430). In other aspects, depending onthe predetermined case unit output sequence, the bot 110 places bothcase unit(s) CUC, CUD at a common location, such as at one of outputlifts 150B1, 150B2.

Referring to FIG. 16, in accordance with aspects of the disclosedembodiment, storage spaces arrayed on racks along picking aisles areprovided (FIG. 16, Block 1600). Multiple level decks are also provided(FIG. 16, Block 1610), where at least one deck level of the multiplelevel decks communicates with each aisle, where the multiple level decksand aisles define a rolling surface for an autonomous transport vehicleat each level of the multiple level decks. Racks at multiple rack levelsare accessed from a respective roiling surface that is common to themultiple rack levels (FIG. 16, Block 1620), where the racks are disposedalong at least one aisle at each level of the multiple lever decks. Inone aspect, a vertical pitch between rack levels varies for a portion ofa respective aisle. In one aspect, the vertical pitch between at leasttwo rack levels of the portion of the respective aisle is related toanother vertical pitch between at least two other rack levels of anotheraisle portion of the respective aisle so that the autonomous transportvehicle effects multiple picks in an ordered sequence in a common aislepass. In one aspect, the vertical pitch between at least two rack levelsof the portion of the respective aisle is related to another verticalpitch between at least two other rack levels of another aisle portion ofthe respective aisle so that the vertical pitch and the other verticalpitch effects substantially filling a vertical space between themultiple deck levels with stored items.

In accordance with one or more aspects of the disclosed embodiment, anautonomous transport vehicle includes a frame forming a payload sectionconfigured to hold one or more pickfaces; a transfer arm movably mountedto the frame; a drive section connected to the frame; and a controllerconnected to the drive section, the controller being configured toeffect an on-the-fly sortation of pickfaces carried by the autonomoustransport vehicle according to a predetermined case out order sequencewhere the controller commands the drive section so that two or morepickfaces are picked from one or more first case unit holding locationsand placed at one or more different second case unit holding locationsaccording to the predetermined case out order sequence.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to effect picking of the two or more pickfacesin an order that is opposite an order in which the two or more pickfacesare placed.

In accordance with one or more aspects of the disclosed embodiment, thetransfer arm is common to the two or more pickfaces such that thetransfer arm is configured to hold the two are more pickfaces adjacentone another.

In accordance with one or more aspects of the disclosed embodiment, theautonomous transport vehicle further includes a justification memberdisposed within the payload section so as to move transverse to alongitudinal axis of the frame wherein the controller is configured tocontrol a combined movement of the justification member and the transferarm to effect the sorting of the two or more pickfaces carried in thepayload section.

In accordance with one or more aspects of the disclosed embodiment, theautonomous transport vehicle further includes a justification memberconnected to the drive section and the controller, the justificationmember being movably mounted to the frame where the transfer arm and thejustification member are each independently movable relative to eachother.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to control the drive section and effectmovement of the justification member and transfer arm so that theon-the-fly sortation is effected by retention of at least one of the twoor more pickfaces within the payload section while at least another ofthe two or more pickfaces is transferred to or from the payload section.

In accordance with one or more aspects of the disclosed embodiment, thetransfer arm includes a plurality of payload support tines and ismovable between a raised and lowered position, and the justificationmember is configured to extend between the tines when the transfer armis in the lowered position.

In accordance with one or more aspects of the disclosed embodiment, theautonomous transport vehicle further includes a payload bed and ajustification member within the payload section, the payload bedincluding laterally arranged payload supports that extend throughapertures in the justification member.

In accordance with one or more aspects of the disclosed embodiment, thetransfer arm includes payload support tines that are spaced so as to beinterdigitated with the laterally arranged payload supports such that alowered position of the payload support tines transfers the one or morepayload items to the laterally arranged payload supports.

In accordance with one or more aspects of the disclosed embodiment, anautomated storage and retrieval system autonomous transport vehicleincludes a frame having a longitudinal axis and forming a payloadsection configured to hold one or more payload items; a justificationmember disposed within the payload section so as to move transverse tothe longitudinal axis; a transfer arm disposed as least partly withinthe payload section; and a controller connected to the justificationmember and the transfer arm, the controller being configured to controla combined movement of the justification member and the transfer arm toeffect an on-the-fly sorting of the one or more payload items carried inthe payload section.

In accordance with one or more aspects of the disclosed embodiment, thejustification member and the transfer arm are each independently movablerelative to each other.

In accordance with one or more aspects of the disclosed embodiment, thecontroller configured to effect movement of the justification member thetransfer arm so that the justification member is inserted between two ofthe one or more payload items to cause a physical separation of the twoof the one or more payload items.

In accordance with one or more aspects of the disclosed embodiment, thejustification member is configured to bi-directionally move the one ormore payload items transversely within the payload section.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to control movement of the justification memberand transfer arm so that sorting is effected by retention of at leastone of the one or more payload items within the payload section while atleast another of the one or more payload items is transferred to or fromthe payload section.

In accordance with one or more aspects of the disclosed embodiment, thetransfer arm includes a plurality of payload support tines and ismovable between a raised and lowered position, and the justificationmember is configured to extend between the tines when the transfer armis the lowered position.

In accordance with one or more aspects of the disclosed embodiment, theautonomous transport vehicle further includes a payload bed within thepayload section, the payload bed including laterally arranged payloadsupports that extend through apertures in the justification member.

In accordance with one or more aspects of the disclosed embodiment, thetransfer arm includes payload support tines that are spaced so as to beinterdigitated with the laterally arranged payload supports such that alowered position of the payload support tines transfers the one or morepayload items to the laterally arranged payload supports.

In accordance with one or more aspects of the disclosed embodiment, amethod of transporting payload items carried in a payload section of anautonomous transport vehicle having a common transfer arm is provided.The method includes supporting the payload items within the payloadsection; and sorting the payload items within the a load section forordered placement in a storage and retrieval system, wherein sorting thepayload items includes spatially separating at least one of the payloaditems disposed on the common transfer arm from another of the payloaditems and the at least one of the payload items retained on the commontransfer arm while the other of the payload items is transferred fromthe payload section with the common transfer arm.

In accordance with one or more aspects of the disclosed embodiment,sorting the payload items further includes transferring the payloaditems between a payload bed of the autonomous transport vehicle and thecommon transfer arm to effect repositioning of the at least one of thepayload items.

In accordance with one or more aspects of the disclosed embodiment,sorting the payload items further includes inserting a justificationmember between the payload items to effect repositioning of the at leastone of the payload items.

In accordance with one or more aspects of the disclosed embodiment, themethod further includes repositioning at least one of the payload itemsdisposed on the common transfer arm.

In accordance with one or more aspects of the disclosed embodiment, anautomated storage and retrieval system autonomous transport vehiclecomprises: a frame having a longitudinal axis and forming a payloadsection configured to hold one or more payload items; a transfer armthat is common to the one or more payload items, the transfer arm beingdisposed as least partly within the payload section and being configuredto hold the one or more payload items; and a payload item justificationmember disposed within the payload section independent of the transferarm and configured so as to engage at least one of the one or morepayload items and move transverse to the longitudinal axis, wheremovement of the payload item justification member is independent ofmovement of the transfer arm.

In accordance with one or more aspects of the disclosed embodiment, theindependent movement of the justification member effects separation ofat least one of the one or more payload items from another of the atleast one payload items carried in the payload section.

In accordance with one or more aspects of the disclosed embodiment, thepayload item justification member has a payload item justificationmember drive and the transfer arm has a transfer arm drive that isdifferent than the payload item justification member drive, where eachof the payload item justification member drive and the transfer armdrive has an dependent drive axis.

In accordance with one or more aspects of the disclosed embodiment, theautonomous transport vehicle further comprises a controller connected tothe justification member and the transfer arm, the controller beingconfigured to control a substantially simultaneous movement of thejustification member and the transfer arm with different respectivedrives to configured a pickface including at least one of the one ormore payload items.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to control the justification member and thetransfer arm to effect separation of the one or more payload itemscarried in the payload section.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to effect movement of the justification memberand the transfer arm so that the justification member is insertedbetween two of the one or more payload items to cause a physicalseparation of the two of the one or more payload items.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to control movement of the justification memberand transfer arm to effect sorting of the one or more payload items byretention of at least one of the one or more payload items within thepayload section while at least another of the one or more payload itemsis transferred to or from the payload section.

In accordance with one or more aspects of the disclosed embodiment, thejustification member is configured to bi-directionally move the one ormore payload items transversely within the payload section.

In accordance with one or more aspects of the disclosed embodiment, thetransfer arm includes a plurality of payload support tines and ismovable between a raised and lowered position, and the justificationmember is configured to extend between the tines when the transfer armis in the lowered position.

In accordance with one or more aspects of the disclosed embodiment, theautonomous transport vehicle further comprises a payload bed within thepayload section, the payload bed including laterally arranged payloadsupports that extend through apertures in the justification member.

In accordance with one or more aspects of the disclosed embodiment, thetransfer arm includes payload support tines that are spaced so as to beinterdigitated with the laterally arranged payload supports such that alowered position of the payload support tines transfers the one or morepayload items to the laterally arranged payload supports.

It should be understood that the foregoing description only illustrativeof the aspects of the disclosed embodiment. Various alternatives andmodifications can be devised by those skilled in the art withoutdeparting from the aspects of the disclosed embodiment. Accordingly, theaspects of the disclosed embodiment are intended to embrace all suchalternatives, modifications and variances that fall within the scope ofthe appended claims. Further, the mere fact that different features arerecited in mutually different dependent or independent claims does notindicate that a combination of these features cannot be advantageouslyused, such a combination remaining within the scope of the aspects ofthe invention.

What is claimed is:
 1. A method for effecting on-the-fly sortation ofpickfaces comprising: providing an autonomous transport vehicle having apayload section formed by a frame of the autonomous transport vehicle,and holding one or more pickfaces with the payload section; providing atransfer arm movably mounted to the frame; providing a drive sectionconnected to the frame; and effecting, with a controller connected tothe drive section, an on-the-fly sortation of pickfaces carried by theautonomous transport vehicle so as to, on the fly, reorder the pickfacescarried by the autonomous transport vehicle with respect to each otheraccording to a predetermined case out order sequence where thecontroller commands the drive section so that two or more pickfaces arepicked up from one or more first case unit holding locations and placedat one or more different second case unit holding locations according tothe predetermined case out order sequence.
 2. The method of claim 1,further comprising effecting, with the controller, picking up the two ormore pickfaces in an order that is opposite an order in which the two ormore pickfaces are placed.
 3. The method of claim 1, wherein thetransfer arm is common to the two or more pickfaces, the method furthercomprising holding, with the transfer arm, the two or more pickfacesadjacent one another.
 4. The method of claim 1, further comprisingproviding a justification member disposed within the payload section soas to move transverse to a longitudinal axis of the frame andcontrolling, with the controller, a combined movement of thejustification member and the transfer arm to effect the sorting of thetwo or more pickfaces carried in the payload section.
 5. The method ofclaim 1, further comprising providing a justification member connectedto the drive section and the controller, the justification member beingmovably mounted to the frame where the transfer arm and thejustification member are each independently movable relative to eachother.
 6. The method of claim 5, further comprising, with thecontroller, controlling the drive section and effecting movement of thejustification member and the transfer arm so that the on-the-flysortation is effected by retention of at least one of the two or morepickfaces within the payload section while at least another of the twoor more pickfaces is transferred to or from the payload section.
 7. Themethod of claim 5, further comprising: moving the transfer arm between araised and lowered position, where the transfer arm includes a pluralityof payload support tines, wherein the justification member extendsbetween the payload support tines when the transfer arm is in thelowered position.
 8. The method of claim 1, further comprising providinga payload bed and a justification member within the payload section, thepayload bed including laterally arranged payload supports that extendthrough apertures in the justification member.
 9. The method of claim 8,further comprising providing the transfer arm with payload support tinesthat are spaced so as to be interdigitated with the laterally arrangedpayload supports and transferring the one or more pickfaces to thelaterally arranged payload supports by lowering the payload supporttines to a lowered position.
 10. A method for effecting on-the-flysortation of payload items comprising: providing an autonomous transportvehicle having a payload section formed by a frame of the autonomoustransport vehicle, the frame having a longitudinal axis, and holding oneor more payload items with the payload section; providing ajustification member disposed within the payload section to movetransverse to the longitudinal axis; providing a transfer arm disposedat least partly within the payload section; and controlling, with acontroller connected to the justification member and the transfer arm, acombined movement of the justification member and the transfer arm toeffect an on-the-fly sorting of the one or more payload items carried inthe payload section with respect to each other.
 11. The method of claim10, wherein the justification member and the transfer arm are eachindependently movable relative to each other.
 12. The method of claim10, further comprising effecting, with the controller, movement of thejustification member and the transfer arm so that the justificationmember is inserted between two of the one or more payload items to causea physical separation of the two of the one or more payload items. 13.The method of claim 10, further comprising bi-directionally moving, withthe justification member, the one or more payload items transverselywithin the payload section.
 14. The method of claim 10, furthercomprising controlling, with the controller, movement of thejustification member and the transfer arm so that sorting is effected byretention of at least one of the one or more payload items within thepayload section while at least another of the one or more payload itemsis transferred to or from the payload section.
 15. The method of claim10, further comprising: moving the transfer arm between a raised andlowered position, where the transfer arm includes a plurality of payloadsupport tines, wherein the justification member is configured to extendbetween the payload support tines when the transfer arm is in thelowered position.
 16. The method of claim 10, further comprisingproviding a payload bed within the payload section, the payload bedincluding laterally arranged payload supports that extend throughapertures in the justification member.
 17. The method of claim 16,further comprising providing the transfer arm with payload support tinesthat are spaced so as to be interdigitated with the laterally arrangedpayload supports and transferring the one or more payload items to thelaterally arranged payload supports by lowering the payload supporttines to a lowered position.
 18. A method for effecting on-the-flysortation of payload items comprising: providing an autonomous transportvehicle having a payload section formed by a frame of the autonomoustransport vehicle, the frame having a longitudinal axis, and holding oneor more payload items with the payload section; providing a transfer armthat is common to the one or more payload items, the transfer arm beingdisposed at least partly within the payload section and extendingtransverse to the longitudinal axis along an extension path; holdingwith the transfer arm, the one or more payload items, and transferring,with the transfer arm, the one or more payload items to and from thepayload section; and engaging, with a payload item justification member,at least one of the one or more payload items, and moving the payloaditem justification member transverse to the longitudinal axis, wheremovement of the payload item justification member is independent ofmovement of the transfer arm and where the payload item justificationmember is disposed within the payload section so as to cross theextension path of the transfer arm, the payload item justificationmember being independent of the transfer arm.
 19. The method of claim18, further comprising effecting, with the independent movement of thepayload item justification member, separation of at least one of the oneor more payload items from another of the one or more payload itemscarried in the payload section.
 20. The method of claim 18, furthercomprising providing the payload item justification member with apayload item justification member drive and providing the transfer armwith a transfer arm drive that is different than the payload itemjustification member drive, where each of the payload item justificationmember drive and the transfer arm drive has an independent drive axis.21. The method of claim 18, further comprising controlling, with acontroller connected to the payload item justification member and thetransfer arm, a substantially simultaneous movement of the payload itemjustification member and the transfer arm with different respectivedrives to configure pickface including at least one of the one or morepayload items.
 22. The method claim 21, further comprising controlling,with the controller, the payload item justification member and thetransfer arm to effect separation of the one or more payload itemscarried in the payload section.
 23. The method of claim 21, furthercomprising effecting, with the controller, movement of the payload itemjustification member and the transfer arm so that the payload itemjustification member is inserted between two of the one or more payloaditems to cause a physical separation of the two of the one or morepayload items.
 24. The method of claim 21, further comprisingcontrolling, with the controller, movement of the payload itemjustification member and transfer arm to effect sorting of the one ormore payload items by retention of at least one of the one or morepayload items within the payload section while at least another of theone or more payload items is transferred to or from the payload section.25. The method of claim 18, further comprising bi-directionally moving,with the payload item justification member, the one or more payloaditems transversely within the payload section.
 26. The method of claim18, further comprising: moving the transfer arm between a raised andlowered position, where the transfer arm includes a plurality of payloadsupport tines, wherein the payload item justification member extendsbetween the payload support tines when the transfer arm is in thelowered position.
 27. The method of claim 18, further comprisingproviding a payload bed within the payload section, the payload bedincluding laterally arranged payload supports that extend throughapertures in the payload item justification member.
 28. The method ofclaim 27, further comprising providing the transfer arm with payloadsupport tines that are spaced so as to be interdigitated with thelaterally arranged payload supports and transferring the one or morepayload items to the laterally arranged payload supports by lowering thepayload support tines to a lowered position.